Enhanced thermally conductive latex cushioning foams by addition of metal materials

ABSTRACT

Methods and combinations for making and using one or more thermally conductive cellular foam layers comprising flexible cellular foam and metallic material particulates, and said thermally-conductive cellular foam layers may be located on, under, or in cushioning foams and mattresses or placed between on, under, within, or between other layering substrates to increase the overall cooling capability of the composite. The thermally conductive foam may be used in mattresses, pillows, bedding products, medical cushioning foams, and similar materials used in bedding environments.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional application from U.S. patentapplication Ser. No. 14/054,071 filed Oct. 15, 2013, now allowed, whichis a continuation-in-part application of U.S. patent application Ser.No. 13/932,492 (which claims the benefit of U.S. Provisional PatentApplication 61/667,810 filed Jul. 3, 2012 and is a continuation-in-partapplication of U.S. patent application Ser. No. 12/713,586 filed Feb.26, 2010, and issued Jan. 13, 2015 as U.S. Pat. No. 8,933,139) filedJul. 1, 2013, and issued Jan. 13, 2015 as U.S. Pat. No. 8,933,140; and acontinuation-in-part application of U.S. patent application Ser. No.13/932,535 (which claims the benefit of U.S. Provisional PatentApplication 61/667,824 filed Jul. 3, 2012 and is a continuation-in-partapplication of U.S. patent application Ser. No. 12/713,586 filed Feb.26, 2010, and issued Jan. 13, 2015 as U.S. Pat. No. 8,933,139), filedJul. 1, 2013, now abandoned, and all of which are incorporated herein byreference in their entirety.

TECHNICAL FIELD

This invention relates to methods for making and using one or morethermally conductive foam layers comprising flexible cellular foam andmetal material particulates, and said layers are located on, under, orin mattresses and bedding products. This invention more specificallyrelates to various types of thermally conductive foams containing metalmaterial particulates including, but not necessarily limited to,mattresses, pillows, mattress topper pads, quilted toppers, medicalmattresses and other bedding products.

TECHNICAL BACKGROUND

Flexible cellular foams such as open-cell polyurethane flexible foams,closed-cell polyurethane flexible foams, latex foams and melamine foamstypically have low thermal conductivities in the range of about 0.035 toabout 0.060 W/(m K). Materials with low thermal conductivities typicallyfunction as insulators, such as rigid polyurethane foam insulation boardor expanded polystyrene insulation board.

Heat transfer consists of a combination of the phenomena of conduction,convection and radiation. In a cushion or mattress, heat transfer byradiation is not very large. Instead, heat transfer by conduction andconvection are the primary paths for moving heat in and through acushion or mattress. As a person sleeps on a mattress, the compressedfoam underneath the body has reduced air flow paths, and the primarymode of heat transfer in the region below the body is conduction.

Heat is conducted from the body, through the compressed foam anddispersed into cushion or mattress regions where the foam is notcompressed as much, which allows natural convection to occur morereadily to remove heat from the mattress. Due to the low thermalconductivity of foam, this process is slow and requires a largetemperature gradient to drive the conduction of heat at a rate similarto the heat production in a person's body. This results in a largeregion of hot foam around the body which makes the foam uncomfortable.

U.S. Pat. No. 3,255,128 discloses polyurethane foam compositionscontaining small particles of metallic aluminum and methods for treatingthe aluminum particles with phosphoric acid to enhance their usefulnessin polyurethane foam. The phosphate aluminum flake was added toinsulating polyurethane foam panels to decrease the heat flow throughthe panels by reducing absorption of heat and radiation.

U.S. Pat. No. 3,833,951 discloses flameproofed mattresses, pillows andsleeping bags. A metallized heat conductive layer is made by mixing ametal with an aqueous vinyl binder, and the frothed mixture is spread ona polyurethane foam having foam thickness between 0.1 to 1.0 inches anddried around 280° C. The final dried coating is 0.5 to 6 mils inthickness.

U.S. Pat. No. 6,772,825 B2 discloses a support surface for patientcomfort and to maintain a cool skin temperature by having a refrigerantbladder with boiling point between 23 and 35 degrees Celsius containedwithin a bladder, a flexible spacer in the bladder such as polyurethanefoam, and thermally-conductive aluminum or copper metal strips and a topmetal layer located on the outside of the bladder. The strips of metalare used to transfer heat away from refrigerant gas into the surroundingenvironment. Metallic material was not added to the polyurethane foamreactants prior to producing the foam substrate.

It is useful and desirable to develop improved heat transfer in acushion or mattress to provide a cooler and more comfortable sleep.

SUMMARY

There is provided, in one non-limiting form, methods of forming anenhanced thermally-conductive cellular foam (referred as “TC Foam” orthermally-conductive foam) comprised of a flexible polyurethane foamand/or polyester polyurethane foam, which may be open or closed celledin nature, and a plurality of metallic material particulates. Phasechange materials, colorants, plasticizers, and other performancemodifying additives may optionally be incorporated into the TC Foam. TheTC Foam contains a metal material in the range of 0.5% to 70% on aweight basis.

Optionally, the TC Foam may be comprised of a plurality of metalmaterial particulates and a latex foam, which may be of open or closecelled nature. In this embodiment, phase change materials, colorants,plasticizers, and other performance modifying additives may optionallybe incorporated into the TC Foam. The TC Foam contains a metal materialin the range of 0.5% to 70% on a weight basis.

Optionally, the TC Foam may be comprised of a plurality of metalmaterial particulates and a melamine foam, which may be of open or closecelled nature. In this embodiment, phase change materials, colorants,plasticizers, and other performance modifying additives may optionallybe incorporated into the TC Foam. The TC Foam contains a metal materialin the range of 0.5% to 70% on a weight basis.

The metal material to be used in methods and compositions describedherein may be selected from a non-limiting list of aluminum, copper,iron, steel, silver, gold, platinum, nickel, tin, chromium, vanadium,tungsten, and combinations thereof, or derivatives made from any ofthose materials combined with oxygen, halogens, carbon, or silicon, andany combination thereof. The metal material may be flakes, powders,crystalline arrangements, particulates, and combinations thereof.

The TC Foam may be cut or molded in many structures such as, but notlimited to, planar layers, convoluted layers, surface modified layers,3D surface texturing, molded pillows, smooth molded surfaces, moldedsurfaces with regular or irregular patterns, or modified in any way asto generate a desired physical structure such as but not limited to holepunching, channeling, reticulation or other method known to the art offoaming for modifying the structure of foam. The TC Foam may be adheredin the cushion or mattress composite with adhesive or melting of athermoplastic on the foam surface and allowing the thermoplastic tore-solidify and lock the TC Foam in place on the substrate foam.

There is also provided, in a non-restrictive embodiment, combinations ofsuitable layering substrates including, but not limiting to, flexiblepolyurethane foam, latex foam, flexible melamine foam, and othersubstrates (such as fibers in woven or non-woven form) with one or moreTC Foams. Articles that may be manufactured from these combinations ofone or more TC Foams substrates including, but not necessarily limitedto, mattresses, mattress toppers, pillows, bedding products, pet beds,quilted mattress toppers, pillow or mattress inserts, contoured supportfoam or other materials commonly used in the bedding environment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a possible heat transfer pathway in amattress cross section;

FIG. 2 is the first example construction using a cushion and/or mattressapplication;

FIG. 3 is the second example construction using a cushion and/ormattress application;

FIG. 4 is the third example construction using a cushion and/or mattressapplication;

FIG. 5 is the fourth example construction using a cushion and/ormattress application;

FIG. 6 is the fifth example construction using a cushion and/or mattressapplication;

FIG. 7 is the sixth example construction using a cushion and/or mattressapplication;

FIG. 8 is the seventh example construction using a cushion and/ormattress application;

FIG. 9 is the eighth example construction using a cushion and/ormattress application;

FIG. 10 is the ninth example construction using a cushion and/ormattress application;

FIG. 11 is example breakdown of lateral mattress zones in a cushionand/or mattress application;

FIG. 12 is example breakdown of longitudinal mattress zones in a cushionand/or mattress application;

FIG. 13 is an example of a molded pillow product where the entirestructure is molded from TC Foam;

FIG. 14 is an example of a molded pillow product where the TC Foam is aregion or layer within the pillow;

FIG. 15 is an example of a wheelchair seat using TC Foam in itsconstruction; and

FIG. 16 is a picture of TC Foam from Example I with thermally conductiveparticulates incorporated in an open cell flexible polyurethane foam.

It will be appreciated that FIGS. 1-15 are schematic and that thevarious elements are not necessarily to scale or proportion, and thatmany details have been removed or simplified for clarity, and thus themethods and compositions are not necessarily limited to the embodimentsdepicted in the Figures.

Before the methods and compositions are explained in detail, it is to beunderstood that these methods and compositions are not limited in itsapplication to the details of construction and the arrangements of thecomponents set forth in the following description or illustrated indrawings. Also, it is understood that the phraseology and terminologyused herein are for the purpose of description and should not beregarded as limiting.

DETAILED DESCRIPTION

It is useful to develop improved heat transfer in a mattress or beddingto provide a cooler and more comfortable sleep or contact byincorporating one or more TC foam layers comprising a flexible cellularfoam and metal material, such as in the form of particulates, and saidone or more TC foam layers are used on, under, or within mattresses,pillows, bedding products, medical cushioning foams, and similarmaterials used in bedding environments. TC Foam exhibit enhanced heattransfer properties due to possessing an enhanced thermal conductivity.

Flexible cellular foams may be open cell polyurethane foam, closed cellpolyurethane foam, open cell polyester polyurethane foam, closed cellpolyester polyurethane foam, latex foam, melamine foam, and combinationsthereof.

Heat transfer consists of a combination of conduction, convection andradiation. In a mattress or bedding, heat transfer by radiation is notvery large. Instead, heat transfer by conduction and convection are theprimary paths for moving heat in a mattress or bedding. As a personsleeps on a mattress, the compressed foam underneath the body hasreduced air flow paths, and the primary mode in the region below thebody is conduction. Heat is conducted from the body, through thecompressed foam, into mattress or bedding regions where the foam is notcompressed as much, which allows natural convection to occur morereadily to remove heat from the mattress. A cooler and more comfortablesleep may be obtained by increasing the thermal conductivity of amattress or bedding and allowing the heat from the body to migrate awaymore rapidly.

Enhanced heat transfer reduces the amount of a temperature gradient thatis required to generate a given amount of heat flow. This means that forthe same amount of body heat, a mattress or bedding with TC foam will beable to have a lower surface temperature of the foam in contact with aperson, while still conducting the heat away. This will result in acooler sleep.

FIG. 1 is a general representation of a heat transfer path when a personsleeps on a mattress with TC Foam 1 located below the first layer offoam 2. However, FIG. 1 does not represent all the possible combinationsof TC Foams and substrate foams.

TC Foams are comprised of an open or closed celled flexible polyurethaneor polyester foam that has one or more metallic materials (such as inthe form of particulates) dispersed throughout the foam. The term“dispersed” covers random dispersions, uniform dispersions, andcombinations thereof of the metallic material particulates in the foam.The TC Foam contains metal material in the range of about 0.5%independently to about 70% on a weight basis. Alternatively, the TC Foamcontains metal material in the range of about 1% independently to about55%, and in another non-limiting embodiment in the range of about 2.5%independently to about 40%, and in a different non-restrictive versionin the range of about 4% independently to about 25%. The term“independently” as used in association with various ranges herein meansthat any lower threshold may be combined with any upper ratio to form asuitable alternative range.

The thermal conductivity of metals is isotropic. The thermalconductivities in all directions in a metal are approximately 5-440W/(m-° K). The thermal conductivity of polyurethane foam is alsoisotropic with thermal conductivities in all directions of about0.035-0.06 W/(m-° K).

Addition of a highly thermally conductive metallic material in a cushionor mattress provides a cooler and more comfortable sleep. The specificmetals of interest have thermal conductivities in the range of 5-440W/(m-° K). If the thermal conductivity of the metallic additives areapproximately 200 W/(m-° K), the metallic additives have about 1,500times the thermal conductivity of foam. Metallic materials are generallyanisotropic in nature exhibiting approximately the same thermalconductivity in all directions.

In one non-limiting embodiment, the TC foam (foam plus metal materialparticulates dispersed therein) may be at least about 0.01 W/(m-° K)higher than the flexible cellular foam with the absence of metalmaterial particulates; alternatively at least about 0.005 W/(m-° K)higher than the flexible cellular foam with the absence of metalmaterial particulates; and in another non-restrictive version, at leastabout 0.002 W/(m-° K) higher than the flexible cellular foam with theabsence of metal material particulates.

The term metals shall be taken to mean an element or its oxides,compound, or alloy or combination thereof that exhibits good thermalconductivity (k>5 W/(m-° K)), and may, but is not necessarily requiredto, exhibit good electrical conductivity (resistivity, ρ<10⁻² Ω·m).

Metal materials may include, but are not necessarily limited to,lithium, sodium, potassium, rubidium, caesium, francium, beryllium,magnesium, calcium, strontuim, barium, radium, zinc, molybdenum,cadmium, scandium, titanium, vanadium, chromium, manganese, iron,cobalt, nickel, copper, yttrium, zirconium, niobium, technetium,ruthenium, rhodium, palladium, silver, hafnium, tantalum, tungsten,rhenium, osmium, iridium, platinum, gold, mercury, rutherfordium,dubnium, seaborgium, bohrium, hassium, copernicum, aluminum, gallium,indium, tin, thallium, lead, bismuth, polonium, lanthanum, cerium,praseodymium, neodymium, promethium, samarium, europium, gadolinium,terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium,actinium, thorium, protactinium, uranium, neptunium, plutonium,americium, curium, berkelium, californium, einsteinium, fermium,mendelevium, nobelium, lawrencium, meitnerium, darmstadtium,roentgenium, ununtrium, flerovium, ununpentium, livermorium, germanium,arsenic, antimony, astatine, and combinations thereof.

Suitable metal materials may include, but are not necessarily limitedto, aluminum, copper, iron, steel, silver, gold, platinum, nickel, tin,chromium, vanadium, tungsten, or made from any of those materialscombined with oxygen, halogens, carbon, or silicon, or any combinationthereof.

Metal compounds have been used in foam as catalytic materials withcommon materials of this type including, but not necessarily limited to,stannous octoate, dibutyl tin dilaurate, bismuth neodecanoate, and zincoctoate. These catalytic compounds are used in small amounts, typically0.01% to 0.40% of the foam formulation. Additionally, the binding of theion in a catalyst structure greatly restricts its ability to function asan element for enhanced thermal transport.

In a non-limiting embodiment, the metal material can be flake, powder,spherical, crystalline arrangements, or other various particulate forms.A suitable size of metal materials may be between about 0.1independently to about 2000 microns, alternatively between about 1independently to about 1000 microns, and in another non-limitingembodiment between about 80 independently to about 500 microns. Metalsform particulates that tend to be hard and sharp; these are twoproperties that are undesirable in foam. Sharp particulates can causeaccelerated breakdown of the foam by cutting or abrading polyurethaneelastomeric portions or foam struts during typical flexing of foam.Additionally, because these particles are often hard, they can be feltagainst a soft foam creating a rough and sometimes uncomfortabletexture. The specific developments described herein are able to controlthese potentially deleterious effects and produce a flexible open cellpolyurethane foam product that is superior to regular open cellpolyurethane foam in terms of thermal heat transfer capacity. Mostpreferred size of metal materials is less 80 to about 500 microns forreducing accelerated compression fatigue.

The TC Foam may also contain useful amounts of conventionally employedadditives (“property-enhancing additives”) such as plasticized triblockcopolymer gels, stabilizers, antioxidants, antistatic agents,antimicrobial agents, ultraviolet stabilizers, phase change materials,surface tension modifiers such as silicone surfactants, emulsifyingagents, and/or other surfactants, solid flame retardants, liquid flameretardants, grafting polyols, compatible hydroxyl-containing chemicalswhich are completely saturated or unsaturated in one or more sites,solid or liquid fillers, anti-blocking agents, colorants such asinorganic pigments, carbon black, organic colorants or dyes, reactiveorganic colorants or dyes, heat-responsive colorants, heat-responsivepigments, heat-responsive dyes, pH-responsive colorants, pH-responsivepigments, pH-responsive dyes and combinations thereof, fragrances, andviscosity-modifiers such as fumed silica and clays, other TC-enhancingadditives and other polymers in minor amounts and the like to an extentnot affecting or substantially decreasing the desired properties of theTC Foam.

Metallized plasticized triblock copolymer gels may be produced from highviscosity triblock copolymers and metal materials, optionally withdiblock copolymers that have been melted or mixed with a plasticizingagent, such as mineral oil, synthetic oil, etc., and optionally mixedwith additives such as colorants, polyols, etc.

Addition of phase change materials to the TC Foam allows theconstruction composite to store or release energy, which is higher thanheat absorbed or released by heat capacity of the non-thermally enhancedconstruction. Heat is stored if the solid phase change material changesto a liquid, and heat is released when the liquid phase change materialchanges to a solid. The melting point temperature is usually chosen tobe in the 20° C. to 35° C. range to match the human comfort zone. Oncethe solid phase change material melts completely, all of the latent heatis used, and the phase change material must be cooled back down belowits melting point to solidify the phase change material and regeneratefor the next melt cycle. Suitable phase change materials have asolid/liquid phase transition temperature from about −10° F. to about220° F. (about −23° C. to about 104° C.). In another non-limitingversion, the phase change solid/liquid phase transition temperature isfrom about 68° F. to about 95° F. (about 20° C. to about 35° C.).

TC Foams may be prepared by a method or methods including batch-wise orcontinuous pouring in a form, mold or on a bun production line, and inone non-limiting embodiment, the metal material may be incorporated orblended into the polyol blend in a batch-wise or continuous process in ablending system such as a continuous stirred tank, static mixingelements, air mixers, or any other equipment known in the skill of theart that is used for mixing solids and additives with liquids.

The TC Foam can be poured in a standard bun form on a conveyor, pouredin a mold having planar or non-planar surfaces, texturing, and 3Dmodification, or poured in a mold with rods to make the foam perforated.

In one non-limiting embodiment, one or more TC Foams may be added withinor on the surface or in any location within the interior cavity of amold for making molded products such as, but not limited to, pillows,mattresses, or mattress toppers, and individual substrate componentsadded to the mold to react, bind, or encapsulate the TC Foam.

In another non-limiting embodiment, there may be a smooth gradienttransition from a TC foam to a substrate foam of any desired type. By“smooth gradient” is meant that there is no sharp demarcation orboundary between the TC foam and the substrate foam. For anon-restrictive example, a pillow with high TC side and low TC side.Such a gradient dispersion of TC solids in cellular foam may be producedby molded or free rise techniques or combinations of these techniques. Anon-limiting example of a gradient-transition foam is using onepolyurethane reactant stream with a TC additive and one polyurethanereactant stream without a TC additive, injecting the stream with TCadditive in the mold first, followed by injecting the stream without TCadditive in the mold, closing mold, and allowing foam to expand in themold cavity. The resulting molded article would have a higher thermallyconductive region on one side of the foam and a lower thermallyconductive region on the other side of the foam with a gradienttransition between regions. For example, during the summer, a person mayselect the TC side for a cooler pillow; and during the winter, a personmay select the non-TC side to reduce heat transfer from the body. Thegradient transition also provides the benefit of higher thermallyconductivity while reducing the overall cost of the foam article.

Combinations of using both molding and free rise processes include, butare not necessarily limited to producing a TC layer by a free risemethod, cutting it, placing it in a mold, and molding it into a vehicleseat. Alternatively, the mold can be first partially filled with a TCfoam and during the same mold pour, the components may be switched to anon-TC foam-forming formulation.

In another non-limiting example, rotational molding techniques may beused. In a non-limiting embodiment, a mold may be coated with TC foamfollowed up by inserting or forming the substrate within the foam mold.

It will be appreciated that the method described herein is not limitedto these examples, since there are many possible combinations for makingTC Foams with open or closed cell polyurethane foams or polyester foamsthat can be used in cushion foams or mattresses. Further details aboutmaking foams, including gel-foams, and the foam and gel-foamcompositions so made may be seen in U.S. Pat. No. 8,933,139; U.S. Pat.No. 8,933,140; U.S. Pat. No. 9,080,051; and U.S. Patent ApplicationPublication Nos. 2013/0296449, incorporated herein by reference in theirentirety.

Applications of the TC Foam

TC Foam can be manufactured and combined with substrate foams for use ina variety of bedding applications, including but not necessarily limitedto, mattresses, pillows, pillow toppers, mattress toppers, quiltedtoppers, body support foam, or other common bedding materials where acooler feeling foam is desirable.

Layering substrates in combination with one or more TC Foams andoptional property-enhancing materials described herein may find utilityin a very wide variety of applications. Suitable layering substratesinclude, but are not limited to, flexible polyurethane foam, flexiblepolyester polyurethane foam, latex foam, flexible melamine foam, andother substrates (such as fibers in woven or non-woven form), andcombinations thereof. More specifically, in other non-limitingembodiments, the combination of TC Foam and substrate would be suitableas pillows or pillow components, including, but not necessarily limitedto, pillow wraps or shells, pillow cores, pillow toppers, for theproduction of medical comfort pads, medical mattresses and similarcomfort and support products, and residential/consumer mattresses,mattress toppers, and similar comfort and support products, typicallyproduced with conventional flexible polyurethane foam or fiber. All ofthese uses and applications are defined herein as “bedding products”.

Alternatively, articles may be produced such as a vehicle seat cushion,a back support, and a combination thereof, which comprises of a TC foamlayer, flexible cellular foam produced by molding, free rise, andcombinations thereof, and a temperature adjustment system. Thetemperature adjustment system is selected from the group including, butnot necessarily limited to, heating through electrical resistance,cooling through a refrigerant, and a combination of both.

FIG. 1 depicts a heat source 10, presumably a body mass, which isintroducing thermal energy into the standard, open cell viscoelasticfoam layer 2 through conduction. This figure imitates a body lying on amattress 20. The TC Foam 1 draws heat in and uses enhanced thermalconductivity properties to move heat laterally through the mattress. Inturn, heat is conducted and convected through open air cells up throughlayer 2 to the top of the mattress. At this point, natural convectionworks to remove heat from the system. In this example, the viscoelasticlayer 2 and TC Foam 1 are constructed upon another viscoelastic layer 2and a foundation of base prime foam 3.

FIG. 2 is a first example of construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.On top of this is a 2 inch (5 cm) standard, open cell viscoelastic(visco) layer 2. The top layer 1 is a 2 inch (5 cm) layer of TC Foam. Itwill be appreciated that the dimensions given in the examples anddescriptions of the various Figures are merely illustrative and are notintended to be limiting. Throughout the drawings, the same or similarreference numerals will be used for the same or similar structures.

FIG. 3 is the second example construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.On top of this is a 2 inch (5 cm) layer of TC Foam 1 followed by a 2inch (5 cm) layer 2 of standard, open cell viscoelastic foam.

FIG. 4 is the third example construction using a cushion and/or mattressapplication. The base of the section is a prime foam layer 3. On top ofthis is a 2 inch (5 cm) layer of TC Foam 1 followed by a 0.75 inch (1.9cm) layer 3 of prime foam. The top layer is a second 2 inch (5 cm) layerof TC Foam 1.

FIG. 5 is the fourth example construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.On top of this is a 2 inch (5 cm) layer of TC Foam 1 followed by a 2inch (5 cm) layer 2 of standard, open cell viscoelastic foam. The toplayer is a second 2 inch (5 cm) layer of TC Foam 1.

FIG. 6 is the fifth example construction using a cushion and/or mattressapplication. The base of the section is a prime foam layer 3. On top ofthis is a 3 inch layer of TC Foam 1.

FIG. 7 is the sixth example construction using a cushion and/or mattressapplication. The base of the section is a prime foam layer 3. On top ofthis is a 3 inch (7.6 cm) layer of TC Foam 1. The interface 4 betweenthe two layers is a non-planar convolution, which may be made byconvoluting the surface of either or both interfacing layers.

FIG. 8 is the seventh example construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.On top of this is a 2 inch (5 cm) layer of TC Foam 1. The interface 4between the two layers is a non-planar convolution, which may be made byconvoluting the surface of either or both interfacing layers. The top ofthis example is a 2 inch (5 cm) layer 2 of standard, open-cellviscoelastic foam.

FIG. 9 is the eighth example construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.Above this is a 2 inch (5 cm) layer 2 of standard, open-cellviscoelastic foam. On top of this is a 2 inch layer (5 cm) of TC Foam 1.The interface 4 between the two layers is a non-planar convolution,which may be made by convoluting the surface of either or bothinterfacing layers.

FIG. 10 is the ninth example construction using a cushion and/ormattress application. The base of the section is a prime foam layer 3.Above this is a 2 inch (5 cm) layer of TC Foam 1. On top of this isanother 2 inch (5 cm) layer of TC Foam 1. The interface 4 between thetwo layers is a non-planar convolution, which may be made by convolutingthe surface of either or both interfacing layers.

FIG. 11 is an example breakdown of lateral mattress zones or sections ina mattress 110. These zones include: lower body zone or section 112,torso/“belly band” zone or section 114, and head & shoulders zone orsection 116. These zones or sections may or may not include TC Foams,example constructions, other mattress layer constructions, or anyvariation thereof. Furthermore, the zones shown are not limiting, butused as an example to show the possibility of utilizing enhancedthermally dissipating layers in specific areas of cushions and/or amattress.

FIG. 12 is an example breakdown of longitudinal mattress zones 122 and124 in a mattress 120. These zones include left section 122 and rightsection 124. These zones or sections 122 and 124 may or may not includeTC Foams, example constructions, other mattress layer constructions, orany variation thereof. Furthermore, the zones shown are not limiting,but used as an example to show the possibility of utilizing enhancedthermally dissipating layers in specific areas of cushions and/or amattress.

FIGS. 11 and 12 are meant to illustrate the usage of TC Foams indifferent regions of mattresses to enhance thermal conductivity inspecific regions. They are not to be interpreted as limiting designfigures. The exact configuration of these zoned TC Foams would bedependent on the purpose of the mattress construction.

FIGS. 13 and 14 are depictions of molded pillow systems. FIG. 13 is apillow 130 molded entirely out of TC Foam 1. Whereas FIG. 14 shows apillow 140 using TC Foam 1 as a region within the overall pillowstructure 2.

FIG. 15 depicts the use of TC foam in a wheelchair seat cushion 150.

The invention will now be described more specifically with respect toparticular formulations, methods and compositions herein to furtherillustrate the invention, but which examples are not intended to limitthe methods and compositions herein in any way.

Example I

A two component system was obtained from Peterson Chemical Technology.The system consisted of a “B” side (PCT-M142B) containing polyols,surfactants, blowing and gelation catalysts and water, and the “A” side(PCT-M142A) consisted of an isocyanate compound. A pre-blend was made bycombining 103.5 parts of the “B” side with 10 parts of LCF-1, analuminum metal additive particulates (average particle size of about 200microns) obtained from Peterson Chemical Technology, in a 32 oz. (0.95L) mix cup. The components were mixed for approximately 45 secondsbefore adding 43.21 parts of the “A” side component, mixed an additional10 seconds and poured into a 9″×9″ (23 cm×23 cm) cake box and allowed torise and cure in a room temperature environment. A flexible polyurethanefoam was produced with aluminum metal material randomly dispersedthroughout the foam structure. Physical properties such as density, IFD,and airflow were measured. Additionally measures of the static thermalconductivity were obtained by following ASTM E1225 standards formeasurement.

A control foam was produced by an identical procedure but with theomission of the 10 parts of LCF-1 aluminum metal material. This foam wastested by the same procedures and used as a comparative control for theTC Foam.

Example II

A two component system was obtained from Peterson Chemical Technology.The system consisted of a “B” side (PCT-MCFB) containing polyols,surfactants, blowing and gelation catalysts and water, and the “A” side(PCT-MCFA) consisted of an isocyanate compound. A pre-blend was made bycombining 100 parts of the “B” side with 10 parts of copper filament,obtained from Peterson Chemical Technology, in a 32 oz. (0.95 L) mixcup. The components were mixed for approximately 45 seconds beforeadding 46.08 parts of the “A” side component, mixed an additional 10seconds and poured into a 9″×9″ (23 cm×23 cm) cake box and allowed torise and cure in a room temperature environment. A flexible polyurethanefoam was produced with randomly dispersed copper filaments throughoutthe foam structure. Physical properties such as density, IFD, andairflow were measured. Additionally measures of the static thermalconductivity were obtained by following ASTM E1225 standards formeasurement.

A control foam was produced by an identical procedure but with theomission of the 10 parts of copper filament. This foam was tested by thesame procedures and used as a comparative control for the TC Foam.

Discussion of Results

Table 1 shows the formula and test results for the two foams produced byfollowing the procedure of Example I. The results indicate an increasein the thermal conductivity (Static TC) of the control foam by 27.2%,from 0.0478 W/(m-° K) to 0.0608 W/(m-° K). FIG. 16 is a black and whitephotograph of the TC foam produced in Example I, where the aluminummetal particulates were incorporated in an open-cell flexiblepolyurethane foam. The aluminum metal particulates appear black in coloragainst the relatively lighter background foam color.

Table 2 shows the formula and test results for the two foams produced byfollowing the procedure of Example II. The results indicate an increasein the thermal conductivity (Static TC) of the control foam by 41.1%,from 0.0511 W/(m-° K) to 0.0721 W/(m-° K).

TABLE 1 Comparison of Formula and Properties of Control and TC Foam ofEx. I Material Measure Control EX. I “B” Side pbw 103.5 103.5 “A” Sidepbw 43.21 43.21 LCF-1 pbw 0 10 Density lbs/ft³ (kg/m³) 3.45 (55.3 kg/m³)3.62 (58.0 kg/m³) IFD lb_(f)/50 in² (N) 9.1 (41 N)   8.7 (39 N)  Airflow SCFM 4.94 4.30 Static TC W/(m-° K) 0.0478 0.0608

TABLE 2 Comparison of Formula and Properties of Control and TC Foam ofEx. II Material Measure Control EX II “B” Side pbw 100 100 “A” Side pbw46.08 46.08 Copper Filament pbw 0 10 Density lbs/ft³ (kg/m³) 3.13 (50.1)3.45 (55.3) IFD lb_(f)/50 in² (N)  10.1 (45 N)  12.4 (55 N) Airflow SCFM4.14 3.93 Static TC W/(m-° K) 0.0511 0.0721

Many modifications may be made in the methods of and implementation ofthis invention without departing from the spirit and scope thereof thatare defined only in the appended claims. For instance, variouscombinations of phase change materials or phase change additives, gels,polyols, isocyanates, catalysts, metal materials (including sizes andshapes of metal material particulates) and other additives, andprocessing pressures and conditions besides those explicitly mentionedherein are expected to be useful.

The words “comprising” and “comprises” as used throughout the claims isinterpreted “including but not limited to”. The present invention maysuitably comprise, consist or consist essentially of the elementsdisclosed and may be practiced in the absence of an element notdisclosed. In a non-limiting instance, there may be provided a thermallyconductive (TC) foam that consists essentially of or consists of aflexible cellular foam, and a plurality of metal material particulatesdispersed in the flexible cellular foam in an amount effective toimprove the thermal conductivity of the flexible cellular foam, wherethe TC foam has improved thermal conductivity as compared to anotherwise identical flexible cellular foam with an absence of the metalmaterial particulates, where the improved thermal conductivity is atleast 0.002 W/(m-° K) higher than the flexible cellular foam with anabsence of the metal material particles.

Alternatively, a thermally conductive (TC) latex foam may consistsessentially of or consists of a cross-linked latex foam and a pluralityof metal material particulates dispersed in the cross-linked latex foamin an amount effective to improve the thermal conductivity of thecross-linked latex foam, where the TC latex foam has improved thermalconductivity as compared to an otherwise identical latex foam with anabsence of the metal material particulates, where the improved thermalconductivity is at least 0.002 W/(m-° K) higher than the cross-linkedlatex foam with an absence of the metal material particles.

There may also be provided a thermally conductive (TC) melamine foamconsisting essentially of or consisting of a cross-linked melamine foamand a plurality of metal material particulates dispersed in thecross-linked melamine foam in an amount effective to improve the thermalconductivity of the cross-linked melamine foam, where the TC melaminefoam has improved thermal conductivity as compared to an otherwiseidentical melamine foam with an absence of the metal materialparticulates, where the improved thermal conductivity is at least 0.002W/(m-° K) higher than the cross-linked melamine with an absence of themetal material particles.

What is claimed is:
 1. A thermally conductive (TC) latex foamcomprising: a cross-linked latex foam; and a plurality of metal materialparticulates dispersed in the cross-linked latex foam in an amounteffective to improve the thermal conductivity of the cross-linked latexfoam, where the TC latex foam has improved thermal conductivity ascompared to an otherwise identical latex foam with an absence of themetal material particulates, where the improved thermal conductivity isat least 0.002 W/(m-° K) higher than cross-linked latex foam with theabsence of the metal particulates.
 2. The TC latex foam of claim 1 wherethe TC latex foam is produced by a method comprising: introducing theplurality of metal material particulates into a mixture of latexfoam-forming components; and polymerizing the latex foam-formingcomponents to form the TC latex foam.
 3. An article of manufacturecomprising the TC latex foam of claim 1 where the article of manufactureis selected from the group consisting of medical cushioning foams,mattresses, pillows, bedding products, mattress pillow toppers, quiltedmattress toppers, mattress toppers, and combinations thereof.
 4. The TClatex foam of claim 1 where the TC latex foam is selected from the groupconsisting of an open cell latex foam, closed cell latex foam, andcombinations thereof.
 5. The TC latex foam of claim 1 wherein the metalmaterial is selected from the group consisting of aluminum, copper,iron, steel, silver, gold, platinum, nickel, tin, chromium, vanadium,and tungsten, derivatives of these metal materials combined with anelement selected from the group consisting of oxygen, halogens, carbon,silicon and combinations thereof, and combinations of any of these. 6.The TC latex foam of claim 1 wherein the metal material particulates arein the form of flakes, powders, spherical, crystalline arrangement, andcombinations thereof.
 7. The TC latex foam of claim 1 wherein the metalmaterial particulates have an average particle size of less than 2000microns.
 8. The TC latex foam of claim 1 wherein the metal materialparticulates have an average particle size of between about 1 to about1000 microns.
 9. The TC latex foam of claim 1 wherein the metal materialparticulates are present in the range of 0.5 to 70% by weight in the TClatex foam.
 10. The TC latex foam of claim 1 wherein the metal materialparticulates are present in the range of 0.5 to 25% by weight in the TClatex foam.
 11. The TC latex foam of claim 1 wherein the TC foamcomprises a structure selected from the group consisting of a solidsheet, a perforated sheet, a non-planar sheet, a planar sheet, atextured sheet, and combinations thereof.
 12. The TC latex foam of claim1 wherein the TC foam is adhered to a layering substrate.
 13. The TClatex foam of claim 1 comprising a smooth gradient transition from theTC latex foam to a substrate foam.
 14. The TC latex foam of claim 1where the improved thermal conductivity is at least 0.01 W/(m-° K)higher than cross-linked latex foam with the absence of the metalparticulates.
 15. An article of manufacture selected from the groupconsisting of a cushion foam, a mattress, a mattress topper pad, andcombinations thereof, where the article of manufacture comprises atleast one zone selected from the group consisting of a longitudinalzone, a lateral zone, and combinations thereof, where the at least onezone comprises the TC latex foam of claim
 1. 16. An article ofmanufacture selected from the group consisting of medical cushioningfoams, mattresses, pillows, bedding products, mattress pillow toppers,quilted mattress toppers, mattress toppers, and combinations thereof,where the article of manufacture further comprises at least one layercomprising the TC latex foam of claim
 1. 17. An article of manufacturecomprising: at least one layer comprising a TC latex foam of claim 1;and a component produced by a process selected from the group consistingof molding, free-rise, and combinations thereof; where the article ofmanufacture is selected from the group consisting of a vehicle seatcushion, a back support, and a combination thereof.
 18. An article ofmanufacture comprising: at least one layer comprising a TC latex foam ofclaim 1; a component produced by a process selected from the groupconsisting of molding, free-rise, and combinations thereof; and atemperature adjustment system selected from the group comprising heatingthrough electrical resistance, cooling through a refrigerant and acombination of both; where the article of manufacture is selected fromthe group consisting of a vehicle seat cushion, a back support, and acombination thereof.
 19. A thermally conductive (TC) latex foamcomprising: a cross-linked latex foam; and a plurality of metal materialparticulates dispersed in the cross-linked latex foam in an amountranging from about 0.5 wt % to about 25 wt % in the TC latex foam toimprove the thermal conductivity of the cross-linked latex foam, whereinthe metal material is selected from the group consisting of aluminum,copper, iron, steel, silver, gold, platinum, nickel, tin, chromium,vanadium, and tungsten, derivatives of these metal materials combinedwith an element selected from the group consisting of oxygen, halogens,carbon, silicon and combinations thereof, and combinations of any ofthese, and where the metal material particulates have an averageparticle size range of between about 1 to about 1000 microns, where theTC latex foam has improved thermal conductivity as compared to anotherwise identical latex foam with an absence of the metal materialparticulates, where the improved thermal conductivity is at least 0.01W/(m-° K) higher than cross-linked latex foam with the absence of themetal particulates.
 20. A thermally conductive (TC) latex foamcomprising: a cross-linked latex foam; and a plurality of metal materialparticulates dispersed in the cross-linked latex foam in an amountranging from about 0.5 wt % to about 25 wt % in the TC latex foam toimprove the thermal conductivity of the cross-linked latex foam, whereinthe metal material is selected from the group consisting of aluminum,copper, iron, steel, silver, gold, platinum, nickel, tin, chromium,vanadium, and tungsten, derivatives of these metal materials combinedwith an element selected from the group consisting of oxygen, halogens,carbon, silicon and combinations thereof, and combinations of any ofthese, and where the metal material particulates have an averageparticle size range of between about 1 to about 1000 microns, where theTC latex foam has improved thermal conductivity as compared to anotherwise identical latex foam with an absence of the metal materialparticulates, where the improved thermal conductivity is at least 0.01W/(m-° K) higher than cross-linked latex foam with the absence of themetal particulates, there the TC latex foam is selected from the groupconsisting of an open cell latex foam, closed cell latex foam, andcombinations thereof.